Moth Green

Green 2002 Moth

Local kids get a taste of local chocolate and local energy.

hile doing PV and intermediate technology volunteer work on the island of Grenada, I became fascinated with the cocoa tree. My favorite pastime became simple, kitchenstyle processing of cocoa beans into luscious hot chocolate. After a while, I began to dream of creating a solar powered chocolate factory in the lush, cocoa-producing southern Caribbean.
Grenada Chocolate Co. founders Edmond Brown, Moth Green, and Doug Browne in front of their cottage factory.

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The price for cocoa beans paid to Grenadian producers is marginal compared to the price of fancy chocolate. So I began to fantasize about making dark chocolate with a cooperative that would actually benefit the cocoa farmers. Grenadas world famous cocoa would be used to create top quality, nonexploitive chocolate bars right in Grenada. Four years ago, together with two par tners and a star tup loan, I embarked on this chocolaty journey. Fine chocolate making is a rather Sixteen, 120 watt AstroPower modules provide power complex process involving several directly to DC-driven, chocolate making machines. different machines. Fresh, pulpy cocoa beans are first harvested from the pods growing The Research Stage on cocoa trees. They are then fermented in a large The first step in our chocolate odyssey was to convince wooden box for about seven days, and sun dried. The a couple of big U.S. chocolate factories to allow us to fermentation gives rise to all the chocolate flavors. see their process and machines. Later, we located a couple of textbooks on chocolate manufacturing. The dry cocoa beans are roasted, shelled, and ground Quickly it became clear to us that small-scale together with sugar into a liquidy paste. Pure cocoa machinery for quality chocolate making is no longer butter, pressed from other roasted cocoa beans, is manufactured. The conversion of cocoa beans to bulk added to this paste, and the mixture is further ground, chocolate is only done at very large factories with very tumbled, and slow-cooked for up to 48 hours. The large machines these days. resulting finished liquid chocolate is then tempered, molded, and cooled into chocolate bars. My chocolate dreams and my renewable energy instincts inevitably collided. My new vision was to build a The machines used in the process are the roaster, solar powered chocolate factory. We wanted the most winnower, melangeur (chocolate grinder), cocoa butter efficient machines possible, because chocolate making press, refiner/conche, tempering kettle, and vibration is a very energy-intensive process for a PV system to table. handle. For over two years, we experimented with designing our own chocolate making machines, as well The melangeur is a refurbished antique chocolate as refurbishing a couple of antique machines. grinding machine with two, 500 pound (227 kg), solid
granite rollers. It has a retrofitted, 24 volt permanent magnet motor, and crushes the roasted cocoa beans.

On all these machines, we used DC, permanent magnet motors, which allow efficient direct powering from the PVs or batteries. In my partner Dougs barn in Oregon, we built and tested several generations of machines, including wood-fired roasters, winnowers, grinders, and cocoa butter presses. We tested them by processing cocoa beans we imported from Grenada. After many months, lots of brainstorming, and a few dead ends, we had a machine line we were happy with, and chocolate we were addicted to. We packed up all our machinery and solar-electric equipment, and sent it on a ship to Grenada about two years ago. Building the Factory It was natural to create our little factor y in the countryside village that I had lived in over the years. I built a bamboo house in this village, and had created independent appropriate technology projects here, such as teaching solar cooker and hand-powered water

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Freshly Harvested Cocoa Beans

Fermenting & Drying

Roasting

Winnowing
The author pouring cocoa beans into a homemade roaster. A 24 volt DC motor powers the tumbler, which allows the beans to roast uniformly.

Grinding

pump design in schools and to farmers. I also helped several far-from-the-grid people get acquainted with small photovoltaic power systems for lighting and radio playing in their houses. This village, Hermitage, is also in the heart of the cocoa-growing belt of Grenada. Liquifying Together with my two partners, one from Oregon and one from the same village, I started the Grenada Chocolate Company. We began the transformation of an old, abandoned, concrete building into our chocolate cottage factory. We redesigned the interior of the building to suit our needs piece by piece, simultaneously assembling and wiring our machines. Because of the hot, humid, tropical climate here, we required air conditioning in two special rooms, one for molding and wrapping chocolate bars, and one for storing chocolate for its crucial aging period. We used efficient, mini-split, ductless-type air conditioners (Lennox LX WM 10F-AFAB). This type of room air conditioner is common in Asia and Europe. They are relatively efficient because the compressor is located outside the building. They are similar to central air conditioning systems, but are ductless. The coolant simply circulates through pipes in and out of the building, expanding and getting cold in front of a blower inside, but losing its heat in the compressor outside the building.

Mixing with Sugar

Conching

Pressing

Tempering

Cocoa Butter

Cocoa Powder

Molding

Cocoa Butter Lotions

Finished Chocolate Bars

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control unit on our refiner/conche machine, which we suspect died this way. We designed most of the factorys loads to run on DC power directly, using the grid to charge our batteries when the PVs cannot provide sufficient energy. When the grid fails unexpectedly, we dont have to worry about any type of backup system switchover to keep our machines moving and prevent our chocolate from burning. Unlike the grid, the batteries wont fail abruptly. We also have some AC loads, such as lights and the air conditioners, which we power either with an inverter, the grid directly, or an engine generator. PVs & Wiring We installed sixteen AstroPower, 120 watt PV modules (1.9 KW rated total, at 25C; 77F) on our roof, configured for 24 volts. We made our own mounting system out of treated 2 by 3 lumber. Essentially, we installed another set of rafters on top of the corrugated metal roofing, directly over the actual rafters underneath. We lag bolted them together through the metal. The PVs were first mounted on 1 by 3s the length of the modules, and then laid down and lag bolted across the 2 by 3s. This provided a sturdy mounting and a cooling air gap underneath the modules. It does have the disadvantage of making it less convenient to check the connections in the PV junction boxes. The PVs are interconnected with #10 (5 mm2) stranded wire that is tucked underneath the panels to hide it from

Refurbished antique winnowing machine, retrofitted with 24 volt DC motors (one motor for vibration and one motor for a powerful fan), removes the outer shell of the roasted cocoa beans.

One interesting thing about designing and implementing our electric system was that we did not have to worry about following codes here in Grenada. There are codes for regular AC wiring, but DC systems are so rare that they never made or adopted any codes for DC wiring and PV installation. We simply did a solid and safe job by our own standards, and we were able to create a suitable system for our unique situation. Power System The chocolate factory is on the grid, and there is no provision in Grenada to sell power to the utility. But the grid power is not reliable enough to count on. It can go off for an entire day once or twice a month, and it goes off for fairly brief periods every couple of days. Not only does the grid go off unexpectedly, but the grid transformers around the country are often overloaded. The electric grid in Grenada is designed to run at 230 VAC, 50 Hz. But overloading regularly brings line voltage down as low as 195 V. Sometimes we need to run the generator even when the grid is on to get a sufficient voltage to run our battery charger and refiner machine effectively. We also have to watch out for very low voltage when the grid first comes back on. We had to replace an electronic temperature

Wendy-Ann Edgar pouring sugar into the antique melangeur.

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wire was used for the two different kinds of 120 VAC and the 230 VAC circuits. Balance of Systems The system also includes four Trojan L-16 high-capacity batteries (395 AH at 6 VDC each), a Heliotrope SolPan 110 load center/control system with a Heliotrope CC120, 120 amp charge controller; a Quick Charge 60 amp, 24 volt forklift battery charger: and a Honda propane powered engine generator. The battery bank capacity is relatively small (395 amphours at 24 V) because, for now, we dont have enough solar generating capacity to cover the total consumption of the factory anyway. So the batteries get used as a buffer (a voltage stabilizer), powering loads day and night, while being simultaneously charged by some combination of the PVs and the battery charger. We use a manual-start 5 KW engine generator that we conver ted to be fueled with propane with a spud/regulator kit. The 230 VAC (our grid voltage here in Grenada) output of the generator is connected through a homemade isolation/transfer system that uses two 60 amp receptacles and one 60 amp plug wired to the grid panel. With this setup, the 230 VAC loads can easily be manually switched between the grid and the generator. A 2,400 watt Trace modified square wave inverter is powered by the battery bank. The inverter output is wired to a separate 120 VAC, 60 Hz breaker panel. We wired special inverter-powered 120 VAC receptacles from this panel at various places around the building where we need them. Controls & Warnings The battery charger cycles on and off automatically as needed, using a power relay and a commercial voltage sensing switch. This sensing switch has two setpoints. We set it to turn the charger on when the battery

Edmond Brown works the cocoa butter press. A 24 volt homemade blender (not shown) blends up hot, ground liquid cocoa to feed the press.

the extreme UV. The array is split into two separate 24 V subarrays, each with two #4 (21 mm2) wires attached. The subarrays each have their own 45 amp DC breaker going into the charge controller in the load center. The dual breaker system offers the convenience of comparing the total number of incoming solar amps from the two subarrays by turning one off at a time. This is a nice way to gain some instant reassurance that all the PVs are functioning the same and, therefore, properly. Because the chocolate factory is wired for DC as well as AC, a variety of wiring was used. Several 24 VDC and a couple of 12 VDC circuits for the machines are wired using single conductor, stranded #12, #10, #8, and #6 (3, 5, 8, and 13 mm2) wire from the load center. Romex type

Chocolate Factory Loads

DC Load Volts Amps Average Average Watts Hrs./Day WH/Day

Granite stone chocolate grinder Inverter (for AC loads) Chocolate temper kettle 19 DC CF lights 2 Vent fans Cocoa bean winnower Cocoa butter press 2 Mold cooling fans Cocoa bean roaster Chocolate mold vibrator

24 24 24 24 24 24 24 24 12 12

40.0 960 19.0 456 43.0 1,032 10.5 252 1.3 30 33.3 799 4.0 96 2.0 48 5.0 60 1.5 18

8.0 11.0 4.0 10.0 24.0 0.8 2.0 4.0 2.0 3.0
Total

7,680 5,016 4,128 2,520 720 599 192 192 120 54 21,221

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The AC charger, used for grid backup, sits atop the vented battery box that holds four Trojan L-16Hs.

shortening our batteries lives. We put in an override switch as well, so we can also use the battery charger to top off the batteries in case of bad weather.
The power wall including the SolPan 110 DC load center, which contains a Heliotrope CC-120 charge controller.

An alarm, powered by the battery bank, of course, warns us when the grid goes down. It is activated by a
Two 230 V receptacles allow a choice between utility or generator power. The LED and stereo indicate a hot grid.

voltage drops to 23 volts DC, and to shut off when the voltage reaches 26 volts DC. Because some of the loads are running constantly, we dont try to use the AC charger to top off the batteries. The energy used to raise the voltage of the system higher than necessary for powering the loads would just be lost as heat in the motors and batteries. We also dont want the charger to come on at too high a voltage, so the PVs always get the first chance to power the factory. The batteries seem to stay healthy because, naturally, once in a while we stop making chocolate. Then the PVs get a chance to top off the batteries. The Heliotrope charge controller has an adjustable voltage regulation setpoint, over which it switches to pulse width modulation mode to keep that voltage steady by controlling the current. Below this setpoint, the charger allows the full current from the PVs to enter the batteries. For the first six months, we had the setpoint at 29 volts. This seemed safe and practical for our Trojan L-16 deep-cycle batteries. But we found that the batteries were drying fast, needing watering quite often, presumably due to the very high average ambient temperature here. We have since lowered the setpoint to 28 volts to avoid

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The voltage sensors and controls for the low voltage disconnect and AC battery charger.

press, and the winnowing machine, are routed through 75, 75, 45, and 30 amp DC-rated breakers, respectively, in the load center. We also added two, five-circuit fuse blocks inside the load center. One is used for additional, low power 24 VDC loads such as the roasters rotation motor and DC lights. A Solar Converters, 24 to 12 volt buck converter (DC-to-DC voltage converter) powers a few small 12 VDC loads via the second fuse block. The inverters DC input is routed through a 175 amp breaker, which is also located inside the load center. The generator produces 230 VAC at 60 Hz. The air conditioners are 230 VAC, 50 Hz. The AC compact fluorescents (CFs) are 120 VAC, 60 Hz. We are mixing and matching frequencies between several of our appliances except for the AC CFs, which are always powered by the 120 VAC, 60 Hz inverter. Our loads dont seem to care. In Grenada, tools and appliances and the like are imported from both the U.S. and Europe, so you never know what you might find. Many houses have 230 to 120 VAC transformers to run their fridges, TVs, stereos, etc. Some of our tools, as well as some of the components we put into our chocolate machines, need 120 VAC.

normally closed relay that is usually held open by power from the grid panel. When the grid goes off, the relay closes the alarm circuit, telling us that we need to watch what is going on and start the generator if necessary. If a grid outage went unnoticed, the battery bank could be depleted after some hours, and our low voltage disconnect system (LVD) would come into play. For our LVD system, we use another voltage controlled switch and an electric car contactor. After the low voltage dsconnection, if it gets sunny enough or the generator is started and the battery charger comes on, the voltage goes right up, and the contactor turns on the factory. Not only do we have to be alerted when the grid goes off, but we also need a grid-back-on-alarm. Without it, we wouldnt know when we could stop the generator and save propane. So we installed a fused, 230 V LED outlet directly to the large, grid powered receptacle of the transfer system. When the grid comes back on, this special outlet turns on. Either the lit LED or a radio plugged into the outlet alerts us that the grid is on again. The Loads We use several types of electricity at the factory. Our larger DC loads, including the chocolate grinder (melangeur), the tempering kettle, the cocoa butter

To cover all situations, we wired the factory with two types of 120 VAC. Some 120 VAC outlets are powered by the inverter, and others are powered by the grid or the generator through a step-down transformer (so we have 120 volts at 50 Hz from the grid or 60 Hz from the inverter). Some of our lights in the factory are powered by the inverter. Other lights are DC. All the lights are compact Chocolate Factory System Costs
Item Cost (US$)

16 AstroPower 120 W modules Trace DR2424 modified square wave inverter Honda EG5000X generator Heliotrope load center w/ controller 4 Trojan L-16H batteries, 395 AH Quick Charge battery charger 2 Solar Converters voltage-sensing switches U.S. Carburetion propane fuel adaptor kit KTA Services electric car contactor Solar Converters buck converter, 24/12 V Charger turn-on relay Alarm activation relay

$8,640 1,285 1,200 1,175 840 520 300 275 145 140 32 11

Total $14,563

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Grenada Chocolate olate Company System

Utility Grid In: 230 volts AC, 50 Hz

Photovoltaic Array: Sixteen AstroPower 120 watt PV modules wired for 1,920 rated watts at 24 volts DC Breakers: Two 45 amp PV array breakers DC Load Center: SolPan 110, with integrated charge controller

KWH Meter

28.6
PWM Taper Charge

Equipment grounds not shown. Gridback-on alarm

Relay Charge Controller: Heliotrope CC-120, 120 amp PWM

Propane Generator: Honda EG5000X, 5,000 watts at 230 volts AC, 60 Hz Batteries: Four Trojan L16H lead-acid batteries, wired for 395 AH at 24 volts DC

LVD Voltage Sensor Buck Converter: 24 VDC to 12 VDC

230 VAC Plug: For choosing grid or generator power

Breakers: various amps, to 24 volt DC loads DC Load Panel: 15 A fuses, to small 24 volt DC loads

Main Fuse: 400 amp

DC Load Panel: 15 A fuses, to small 12 volt DC loads

G N H

Main Disconnect: manually opens LVD

Inverter: Trace DR2424 modified-square wave inverter, 2,400 watts at 120 volts AC, 60 Hz

trace

DR 2424

Transformer: 230 volts to 120 volts AC AC Load Center: 15 amp breakers to 120 volt AC, 50 Hz loads

AC Load Center: 15 and 30 amp breakers to 230 volt AC, 50 & 60 Hz loads

AC Load Center: 15 amp breakers to 120 volt AC, 60 Hz loads

Voltage Sensor Relay

AC Battery Charger: 60 amps at 24 VDC, controlled by voltage sensing relay

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fluorescents, of course. Our chocolate refiner (conche) machine, the battery charger, and the air conditioners run on 230 VAC directly off the grid or generator. Four Voltages With all the various requirements for our factorys equipment, we actually ended up having four different voltages and two frequencies of 120 VAC! The grid and our air conditioners are 230 VAC. Our inverter and our transformer provide us with 120 VAC modified square wave 60 Hz, and 120 VAC sine wave 50 Hz, respectively. We have various components, controls, and tools that use 120 VAC. Some of them prefer 60 Hz, while others would rather have a true sine wave at 50 Hz to operate properly. Most of the machines and lights use 24 VDC, our systems nominal voltage. But one of the permanent magnet gear motors that we needed was only available in 12 VDC. Thats why we installed the 12 VDC fuse block inside the load center. It is handy anyway because a lot of the DC tools and appliances we can find, such as fans, are 12 V.

Being situated on a little island in the sea causes us to end up with motors and other devices imported from all over the world with various voltages. By having all the common voltages, we can cover almost any situation as we continue to tinker and figure out the best way to expand our operations output. Its a complicated system, and not something Id recommend in most cases. Future Solar Plans Who said its not practical to power air conditioners with PVs? The mini-split type we use is quite efficient. Our 9,000 BTU per hour unit only draws 970 watts, and cycles off quite often in our small insulated room. My ballpark estimate is that each air conditioner is on about a quarter of the time on the average, or a total of twelve hours per day for the two units. This gives an approximate total of 11.6 kilowatt-hours per day. With a large 230 volt inverter and another 6 kilowatts of PV, we should be able to solar power the entire factory, including the air conditioners, most days of the year down here in the sunny Caribbean.

We needed a way to keep our chocolate at about 70F (21C) when selling at beach parties. Thermoelectric coolers, commonly used by truck drivers to keep drinks cool, are perfect for use with PVs because they cool mildly and use little power. A phenomenon known as the Peltier effect causes one side of a thermoelectric module to get hot and the other cold when electric current is applied. When the module is coupled with a heat sink on one side and a heat conductive plate on the other, it acts like a heat pump, keeping the inside of the cooler cool. We added thermoelectric cooling to a regular cooler (Coleman, US$55) by incorporating an aluminum plate (scrap yard, US$8), a Peltier cooling module (US$15), a block of aluminum (scrap yard, US$6), a heat sink (US$10), and a 12 V muffin fan (US$9) into one wall of the cooler. A square chunk of the cooler wall and insulation was cut out to accommodate the unit. The 2 by 2 inch (5 x 5 cm) Peltier module and the block of aluminum were placed where the insulation was, with the cold side of the module facing in against the aluminum plate, which was mounted on the inside of the cooler. The hot side of the module faces out against the aluminum block. The other side of the aluminum block contacts the heat sink, mounted on the outside of the cooler, with the fan attached. Thermal conductive compound was applied to all meeting surfaces. A 55 watt Siemens PV module (US$330) is connected directly to the positive and negative

terminals of the thermoelectric module and the fan in parallel, using #12 (3.3 mm2) wire. The nice thing about a PV powered thermoelectric unit is that the more current available to the module, the colder it will get. When it is sunniest and hottest, we get the most cooling power. The maximum cooling happens at 5.5 amps for this thermoelectric module. So we get less than half its full effect from the single 55 watt PV module, which seems to be enough if we are in the shade. If we need extra cooling power, we could just add another PV module. Peltier effect cooler and PV panel.

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Another difficulty is that we have to store sacks of cocoa beans for months during the off-season. They spoil quickly in this very hot, humid, tropical environment. There is certainly not enough space in our little air conditioned rooms to store cocoa beans. So we plan to get a small cargo ship container and convert it into an independently PV powered, air conditioned, cocoa bean storage unit. Well need approximately 2 kilowatts of PV (which will shade the roof of the container as well), another 230 volt inverter, a separate set of batteries, and another mini-split air conditioner. Large PV systems like this are expensive, of course, but if the loans to acquire them are attainable, we see them as buying our chocolate making energy long in advance. Chocolate Power! Finally, after years of tinkering, munching on chocolate, and sweating profusely, we have completed the factory and successfully tested all systems. Our little chocolate making cooperative can crank out about 300 pounds (136 kg) of chocolate and cocoa powder every week, enough for the local and tourist markets. One month after our product launching, we are feeling very encouraged. The foreigners and tourists are impressed with our products, since they are used to dark chocolate. Grenadians themselves are just getting used to the idea. Only low quality milk chocolate has ever been imported, and we are the first chocolate company in Grenada. Its fun that people here can finally enjoy the luxury of high quality chocolate after supplying the fancy European chocolate companies with cocoa beans for over a century. Grenadas cocoa is some of the strongest in the world. It is also particularly clean cocoa, very rarely sprayed with pesticides. Eventually we will export our chocolate, but for now, we will just be keeping up with the local market. We are probably the smallest chocolate factory in the world, and perhaps the only solar powered one. Access Moth Green, The Grenada Chocolate Company, Ltd., Hermitage, St. Patricks, Grenada, West Indies 473-442-0050 moth@grenadachocolate.com www.grenadachocolate.com AstroPower, Inc., Solar Park, 461 Wyoming Rd., Newark, DE 19716 866-218-2797 or 302-366-0400 Fax: 302-368-6474 sales@astropower.com www.astropower.com PV modules Trojan Battery Company, Inc., 12380 Clark St., Santa Fe Springs, CA 90670 800-423-6569 or 562-946-8381 Fax: 562-906-4033 marketing@trojanbattery.com www.trojan-battery.com Batteries

Doug Browne and Wendy-Ann Edgar wrap finished solar powered chocolate, and try not to eat too much.

Xantrex Technology, Inc., Distributed Residential and Commercial Markets, 5916 195th St. NE, Arlington, WA 98223 360-435-8826 Fax: 360-435-2229 inverters@traceengineering.com www.xantrex.com Inverter Solar Converters, Inc., C1-199 Victoria Rd. S., Guelph, ON, Canada, N1E 6T9 519-824-5272 Fax: 519-823-0325 info@solarconverters.com www.solarconverters.com Voltage controlled switches (model VCS-2) and buck converter, 24 to 12 volts (model EQ 12/24-20) KTA Services, Inc., 944 West 21st St., Upland, CA 91784 909-949-7914 Fax: 909-949-7916 www.kta-ev.com Electric car contactor and main battery fuse. Quick Charge Corp., 1032 S.W. 22nd St., Oklahoma City, OK 73109 800-658-2841 or 405-634-2120 Fax: 405-632-5667 contact@quickcharge.com www.quickcharge.com Forklift battery charger Honda Power Equipment Group, 4900 Marconi Dr., Alpharetta, GA 30005 800-426-7701 or 770-497-6400 Fax: 678-339-2670 www.honda.com Generator U.S. Carburetion, Inc., HC79, Box 130, Building B-1, Canvas, WV 26662 800-553-5608 or 304-872-7098 Fax: 304-872-3359 sales@uscarburetion.com www.propane-generators.com Propane fuel conversion spud kit Leeson Electric Corporation, PO Box 241, Grafton, WI 53024 262-377-8810 Fax: 262-377-9025 leeson@leeson.com www.leeson.com Motors

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Scott Motor Company, 2401 S. Virginia St., Reno, NV 89502 888-550-0270 or 775-332-4000 Fax: 775-332-4005 info@scottmotors.com www.scottmotors.com Motors W. W. Grainger, Inc., 100 Grainger Parkway, Lake Forest, IL 60045 847-535-1000 postoffice@grainger.com www.grainger.com Dayton motors McMaster-Carr Supply Company, Inc., PO Box 740100, Atlanta, GA 30374 404-346-7000 Fax: 404-349-9091 atl.sales@mcmaster.com www.mcmaster.com Various relays, pulleys, sprockets, and other assorted machine-building supplies Lennox Air Conditioning, PO Box 799900, Dallas, TX 75379 800-9-LENNOX or 972-497-5000 Fax: 972-497-5331 www.lennox.com Mini-split ductless air conditioners Backwoods Solar Electric Systems, 1395-HP Rolling Thunder Ridge, Sandpoint, ID 83864 208-263-4290 Fax: 888-263-4290 info@backwoodssolar.com www.backwoodssolar.com Siemens PV module for solar cooler, SolPan load center, and CFs Marlin P. Jones & Assoc., Inc., PO Box 12685, Lake Park, FL 33403 800-652-6733 or 561-848-8236 Fax: 800-432-9937 mpja@mpja.com www.mpja.com Thermoelectric cooling module, muffin fan, heat sink

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